Electrode structure

ABSTRACT

An electrode structure of a fuel cell for power generation comprises an anodic structure, a cathodic structure, and an ionic exchange membrane disposed between the anodic and cathodic structures. The anodic and cathodic structures respectively are formed by multi-layer structures, to reduce the fuel crossover from the anodic structure to the cathodic structure, to reduce the catalysts applied amount, and to increase an output electrical energy of the fuel cell. The multi-layer structure of the anodic structure comprises a thin platinum alloy black layer, a Pt alloy layer disposed on the carbon material, and a substrate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Divisional of pending U.S. patent application Ser.No. 11/618,154, filed Dec. 29, 2006 and entitled “ELECTRODE STRUCTURE”.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to an electrode structure, and in particular to anelectrode structure of a fuel cell for power generation.

2. Description of the Related Art

In general, fuel cells having an anodic structure, a cathodic structureand an ionic exchange membrane generate power by converting chemicalenergy to electrical energy by electro-chemical reaction therebetween.In the process of electro-chemical reactions have the fuel oxidation andoxygen reduction. The fuel oxidation reaction of the anodic structurereleases hydrogen ions, electrons and carbon dioxides. The oxygenreduction reaction of cathodic structure combines with anodic hydrogenions, and the electrons releases water. In a conventional fuel cell,however, crossover of the liquid, colloidal, solid or gaseous organicfuel (e.g., alcohol, aldehyde or acid) from the anodic to cathodicstructure is inevitable. Part of the fuel and water without reactingwith the anodic catalyst directly pass through the ionic exchangemembrane and reach the cathodic structure, resulting in a decrease ofthe catalytic reaction performance of the cathodic structure. A mixedpotential is formed by the fuel on the cathodic structure producedoxidation reaction and with the nearby oxygen produced reductionreaction, thus reducing output voltage, output electrical power and fuelutilization of the fuel cell. Further, crossover of fuel results in theswell of the electrode adhesive between the cathodic electrode and theionic exchange membrane, thus accelerating aging of the cathodicstructure.

In FIG. 1A, a conventional anodic structure A1 of an organic fuel cellsequentially comprises a substrate 111, a platinum alloy carbon supportlayer 112 and an ionic exchange membrane 2. The platinum alloy carbonsupport layer 112 disposed next to the ionic exchange membrane 2comprises pluralistic carbon support particles 116, each covered bypluralistic platinum alloy particles 115 and appropriately polymers 118.The platinum alloy particles 115 catalyzed the liquid, gel, solid orgaseous organic fuel, e.g. alcohol, aldehyde or acid, of the anodicstructures A1 to produce oxidation reaction. Because the platinum alloyparticles 115 of the platinum alloy carbon support layer 112 areoptimally distributed on the carbon support particles 116, the effectivecatalytic area and availability of the platinum alloy particles 115increases. In FIG. 1B, a reference signal D1 represents a fuel path whenthe fuel travels through the platinum alloy carbon support layer 112.Due to the larger size of carbon support particles 116 and larger poresizes therebetween, the fuel path D1 is relatively short. In FIG. 1C, areference signal B1 represents a fuel concentration curve when the fueltravels through the anodic structure A1. The utilization of the platinumalloy particles 115 of the platinum alloy carbon support layer 112 ishigh and the fuel path D1 is relatively short, resulting in a smoothlydeclining fuel concentration curve B1.

In FIG. 2A, an anodic structure A2 sequentially comprises the substrate111 and a platinum alloy black layer 121 disposed next to the ionicexchange membrane 2. The platinum alloy black layer 121 comprises theplatinum alloy particles 115 and appropriately polymers 118. Because theplatinum alloy particles 115 tend to aggregate, the inside of theaggregated platinum alloy particles 115 cannot react with the fuel, andthus the effective catalytic area of the aggregated platinum alloyparticles 115 is low, i.e., the availability of the platinum alloyparticles 115 decreases. In FIG. 2B, a reference signal D2 represents afuel path when the fuel travels through the platinum alloy black layer121. Because the platinum alloy particles 115 are small and the poresizes between are tortuously, the fuel path D2 of the fuel travelingthrough the platinum alloy black layer 121 is relatively long. In FIG.2C, a reference signal B2 represents a fuel concentration curve when thefuel travels through the anodic structure A2. The utilization of theplatinum alloy particles 115 of the platinum alloy carbon support layer112 is low and the fuel path D2 is relatively long, resulting in asharply declining fuel concentration curve B2.

FIG. 3 shows a discharge interval of the cathode and anode potentials ofthe fuel cell. A reference signal VA represents a theoretical potentialof cathodic oxygen reduction, and a reference signal VB represents apractical potential of cathode discharge. The distance is between thetheoretical potential VA and the practical potential VB of cathodedischarge is an over-potential caused by cathodic oxygen reduction. Areference signal VC represents a practical potential of anodedischarging, and a reference signal VD represents a theoreticalpotential of the fuel. The distance is between the practical potentialVC of anode discharging and the theoretical potential VD of the fuel isan overpotential caused by fuel oxidation reaction. The distance betweenthe cathodic practical potential VB and the anodic practical potentialVC is an output voltage of the discharge fuel cell.

There is fuel oxidation reaction in the cathode, when the fuel of anodicstructure permeates through the cathodic structure. The cathodicpractical potential VB has gone down and the output voltage of the fuelcell has decreasing. It is understood that crossover of the fuel fromthe anodic structure throughout the cathodic structure is an unwantedsituation.

The platinum alloy carbon support layer 112 of the anodic structures A1or the platinum alloy black layer 121 of the anodic structure A2 must bethickened can solve the problems such as fuel crossover caused by thedescribed liquid, gel, solid or gaseous organic fuel (e.g., alcohol,aldehyde or acid) The fuel path D1 is relatively short and the thickenedplatinum alloy carbon support layer 112 can avoid the crossover of thefuel, however, cracks form on the platinum alloy carbon support layer112 and lowers the utilization of the catalyst adjacent to the ionicexchange membrane 2 when the platinum alloy carbon support layer 112 istoo thick.

Note that the fuel path D2 of the anodic structure A2 is longer than thefuel path D1 of the anodic structures A1. If the platinum alloy blacklayer 121 of the anodic structure A2 is thickened, the product of fuelreaction, e.g. carbon dioxide, requires more time to travel through thefuel path D2, thus, the efficiency of the fuel cell decreases. Ingeneral, the cost of the platinum alloy carbon support layer 112 or theplatinum alloy layer black 121 is substantially 70% of the totalmaterial of a fuel cell. Thus, the thickened platinum alloy carbonsupport layer 112 or the thickened platinum alloy black layer 121increases the fuel cell material cost.

Based on the defects caused by the described fuel crossover of theliquid, gel, solid or gaseous organic fuel, e.g. alcohol, aldehyde oracid and the low catalyst utilization, the invention provides anelectrode structure utilizing a small amount of catalyst in a catalyticlayer to lower fuel crossover, consume the fuel in the anodic structure,avoid the fuel from the anode structure diffusion to the cathodicstructure, increase the output voltage of the fuel cell.

BRIEF SUMMARY OF THE INVENTION

The aim of the invention at the provides an electrode structure appliedto fuel cell, decreased the fuel of the liquid, gel, solid or gaseousorganic fuel, e.g. alcohol, aldehyde or acid crossover. It can increasethe output voltage of the fuel cell and power density, and than decreasethe total material cost of the fuel cell caused by lessen catalystamount.

An electrode structure of a fuel cell for power generation comprises ananodic structure, a cathodic structure, and an ionic exchange membranedisposed between the anodic and cathodic structures. The anodicstructure sequentially comprises a thin platinum alloy black layerdisposed next to the ionic exchange membrane, a platinum alloy carbonsupport layer and a substrate layer. The thin platinum alloy black layercomprises plurality of platinum alloy particles and appropriatelypolymers. The platinum alloy particles applied to catalyze the anodecatalyst by platinum (Pt) combined with components such as Sn, Mo, Rh,W, Pd, Ir or Au. The thin platinum alloy black layer is a thin and densecatalyst layer.

The invention provides an electrode structure having a low fuelcrossover and high reaction discharge efficiency with respect to theconventional anode structure, to eliminate aging of the cathodestructure.

A detailed description is given in the following embodiments withreference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be more fully understood by reading the subsequentdetailed description and examples with references made to theaccompanying drawings, wherein:

FIG. 1A is a schematic view of a conventional anodic structure (A1) of afuel cell;

FIG. 1B is a schematic view of a fuel path (D1) of the anodic structure(A1) when the fuel travels through a platinum alloy carbon support alloylayer;

FIG. 1C is a schematic view of fuel concentration variation when thefuel travels through the anodic structure (A1);

FIG. 2A is a schematic view of a conventional anodic structure (A2) of afuel cell;

FIG. 2B is a schematic view of a fuel path (D2) of the anodic structure(A2) when the fuel travels through a platinum alloy black layer;

FIG. 2C is a schematic view of fuel concentration variation when thefuel travels through the anodic structure (A2);

FIG. 3 is a schematic view of a voltage of a fuel cell;

FIG. 4 is a schematic view of an electrode structure (100) of a fuelcell of the invention;

FIG. 5A is a schematic view of an anodic structure (A3) of theinvention;

FIG. 5B is a schematic view of fuel concentration when the fuel travelsthrough the anodic structure (A3);

FIG. 6A is a schematic view of an anodic structure (A4) of theinvention;

FIG. 6B is a schematic view of fuel concentration variation when thefuel travels through the anodic structure (A4);

FIG. 7A is a schematic view of an anodic structure (A5) of theinvention;

FIG. 7B is a schematic view of fuel concentration variation when thefuel travels through the anodic structure (A5);

FIG. 8 is a schematic view of a cathodic structure (C1) of theinvention;

FIG. 9 is a schematic view of a cathodic structure (C2) of theinvention;

FIG. 10 is a schematic view of a cathodic structure (C3) of theinvention;

FIG. 11 is a schematic view of a cathodic structure (C4) of theinvention;

FIG. 12 is a schematic view of a cathodic structure (C5) of theinvention;

FIG. 13 is a diagram comparing the fuel crossover status between theanodic structure (A5) of the invention and the conventional anodicstructure (A2);

FIG. 14A is a diagram comparing discharge performance at 10% fuelconcentration between the anodic structure (A5) of the invention and theconventional anodic structure (A2);

FIG. 14B is a diagram comparing maximal power density at 10% fuelconcentration between the anodic structure (A5) of the invention and theconventional anodic structure (A2);

FIG. 15A is a diagram of discharge performance at 20% fuel concentrationbetween the anodic structure (A5) of the invention and the conventionalanodic structure (A2);

FIG. 15B is a diagram comparing maximal power density at 20% fuelconcentration between the anodic structure (A5) of the invention and theconventional anodic structure (A2);

FIG. 16A is a diagram of maximal power density of the conventionalanodic structure (A2) at different fuel concentrations;

FIG. 16B is a diagram of maximal power density of the anodic structure(A5) of the invention at different fuel concentrations;

FIG. 17 is a simulated diagram of fuel concentration distribution ofseveral catalytic layers.

DETAILED DESCRIPTION OF THE INVENTION

The following description is of the best-contemplated mode of carryingout the invention. This description is made for the purpose ofillustrating the general principles of the invention and should not betaken in a limiting sense. The scope of the invention is best determinedby reference to the appended claims.

In FIG. 4, a power generation fuel cell of a first embodiment comprisesa fuel (not shown in Figs.) and an electrode structure 100 used toactuate the fuel to generate electricity. The electrode structure 100sequentially comprises a cathodic structure 72, an ionic exchangemembrane 2 disposed next to the cathodic structure 72, and an anodicstructure 71. The anodic structure 71 sequentially comprises a firstthin platinum alloy black layer 711 disposed next to the ionic exchangemembrane 2, a platinum alloy carbon support layer 712 and a firstsubstrate layer 713. The first thin platinum alloy black layer 711 is athin and dense catalyst layer by a plurality of platinum alloy particles(not shown in Figs.). The platinum alloy particles are formed byplatinum (Pt) combined with components such as Sn, Mo, Rh, W, Pd, Ir orAu. The platinum alloy carbon support layer 712 comprises a plurality ofcarbon support particles (not shown in Figs.) which are made ofconductive and anti-corrosive carbon material. The ionic exchangemembrane 2 is made of Nafion®/Nafion® derivatives, non-perfluorochemicals and derivatives thereof, or hydrocarbon, and the firstsubstrate layer 713 can be a carbon substrate. The following anodicstructures A3, A4 and A5 are three exemplary embodiments of the anodicstructure 71.

In FIG. 5A, the anodic structure A3 sequentially comprises a first thinplatinum alloy black layer 132 disposed next to the ionic exchangemembrane 2, a platinum alloy carbon support layer 131, and a firstsubstrate 111. The platinum alloy carbon support layer 131 comprises acarbon support layer 135 containing a first catalytic platinum alloycarbon concentration and disposed next to the first substrate 111, and acarbon support layer 136 containing a second platinum alloy carbonsupport layer and disposed between the carbon support layer 135 and thefirst thin platinum alloy black layer 132. The first catalytic platinumalloy carbon concentration of the carbon support layer 135 is referredto a low catalytic platinum alloy, and the second platinum alloy carbonsupport layer of the carbon support layer 136 is referred to a highcatalytic platinum alloy. The first catalytic platinum alloy carbonconcentration is not greater than the at least one second platinum alloycarbon support layer. The first catalytic platinum alloy carbonconcentration and the second platinum alloy carbon support layer aresubstantially between 10 to 90 wt %. The first catalytic platinum alloycarbon concentration is not less than 10 wt %, and the second platinumalloy carbon support layer is not greater than 90 wt %. In theembodiment, the first substrate 111 can be a carbon substrate such ascarbon paper, carbon cloth, carbon fiber or carbon plate.

To specify the electrode structure in the following description, thecarbon support layer 135 with the first catalytic platinum alloy carbonconcentration is defined as a low catalytic platinum alloy carbonsupport layer, and the carbon support layer 136 with the second platinumalloy carbon support layer is defined as a high catalytic platinum alloycarbon support layer.

The high catalytic platinum alloy carbon support layer 136 comprises aplurality of high platinum alloy carbon support particles 117 and anappropriately polymers 118, and the low catalytic platinum alloy carbonsupport layer 135 comprises a plurality of low platinum alloy carbonsupport particles 133 and an appropriately polymers 118. The first thinplatinum alloy black layer 132 comprises a appropriately polymers 118and a plurality of platinum alloy particles 115, and the platinum alloyparticles 115 are linked by the polymers 118 to form the first thinplatinum alloy black layer 132. The high platinum alloy carbon supportparticles 117 are linked by the polymers 118 to form the high catalyticplatinum alloy carbon support layer 136. The low platinum alloy carbonsupport particles 133 comprise a plurality of carbon support particles116 and the platinum alloy particles 115. The low platinum alloy carbonsupport particles 133 are linked by the polymers 118 to form the lowcatalytic platinum alloy carbon support layer 135. The high platinumalloy carbon support particles 117 comprise the carbon support particles116 and the platinum alloy particles 115. The low platinum alloy carbonsupport particles 133 differs from the platinum alloy particles 115 inthat the amount of the platinum alloy particles 115 of the high platinumalloy carbon support particles 117 is greater than the amount of theplatinum alloy particles 115 of the low platinum alloy carbon supportparticles 133. Additionally, the first thin platinum alloy black layer132 is preferably covered on the surface of the ionic exchange membrane2 or the platinum alloy carbon support layer 131.

In FIG. 5B, a reference signal B3 represents a fuel concentration curvewhen the fuel travels through the anodic structure A3. The fuelconcentration curve B3 obviously declines when the fuel travels throughthe platinum alloy carbon support layer 131 and the first thin platinumalloy black layer 132, i.e., most of the fuel in the anodic structure A3has a complete reaction. The fuel is an available fuel comprisingliquid, gel, solid or gaseous organic fuel, e.g. alcohol, aldehyde oracid. Thus, the crossover can be controlled by regulating the percentageof the low catalytic platinum alloy carbon support layer 135 and thehigh catalytic platinum alloy carbon support layer 136, to increaseperformance of the fuel cell.

In FIG. 6A, the anodic structure A4 sequentially comprises a first thinplatinum alloy black layer 142 disposed next to the ionic exchangemembrane 2, a platinum alloy carbon support layer 141 and a firstsubstrate layer 111. The platinum alloy carbon support layer 141comprises a first non-catalytic carbon support layer 144 and a highcatalytic platinum alloy carbon support layer 145. The combination ofthe first thin platinum alloy black layer 142 and the high catalyticplatinum alloy carbon support layer 145 of the anodic structure A4 issimilar to the combination of the first thin platinum alloy black layer132 and the high catalytic platinum alloy carbon support layer 136 ofthe anodic structure A4 in FIG. 5A. Additionally, the first thinplatinum alloy black layer 142 is preferably covered on the surface ofthe ionic exchange membrane 2 or the platinum alloy carbon support layer141. The first non-catalytic carbon support layer 144 comprises aplurality of carbon support particles 116 and a appropriately polymers118 dispersed on surfaces of the carbon support particles 116, and thecarbon support particles 116 are linked by the polymers 118 to form thenon-catalytic carbon support layer 144. The non-catalytic carbon supportlayer 144 serves as a cubic barrier to block the diffusing fuel, so thatthe diffusion rate of the fuel traveling through the anodic structure A4can be regulated by controlling the thickness and porosity of thenon-catalytic carbon support layer 144. Based on the non-catalyticcarbon support layer 144, the fuel can be completely consumed by thehigh catalytic platinum alloy carbon support layer 145 and the firstthin platinum alloy black layer 142. Additionally, the platinum alloycarbon support layer 141 is preferably a combination of thenon-catalytic carbon support layer 144 and a low catalytic platinumalloy carbon support layer (not shown in Figs.), wherein the lowcatalytic platinum alloy carbon support layer has a configurationsimilar to the low catalytic platinum alloy carbon support layer 135 ofthe anodic structure A3.

In FIG. 6B, a reference signal B4 represents a fuel concentration curvewhen the fuel travels through the anodic structure A4. The fuelconcentration curve B4 obviously declines when the fuel travels throughthe platinum alloy carbon support layer 141 and the first thin platinumalloy black layer 142, i.e., most of the fuel in the anodic structure A4has a complete reaction. Furthermore, the distribution of the fuelconcentration can be controlled by regulating the percentage of thefirst non-catalytic carbon support layer 144 and the high catalyticplatinum alloy carbon support layer 145, to consume the fuel travelingthrough the anodic structure A4 and to increase performance of the fuelcell.

In FIG. 7A, the anodic structure A5 sequentially comprises a first thinplatinum alloy black layer 152 disposed next to the ionic exchangemembrane 2, a platinum alloy carbon support layer 151 and a firstsubstrate layer 111. The platinum alloy carbon support layer 151 can bea high catalytic platinum alloy carbon support layer (not shown inFigs.), wherein the combination of the high catalytic platinum alloycarbon support layer and the first thin platinum alloy black layer 152has a configuration similar to the high catalytic platinum alloy carbonsupport layer 136 and the first thin platinum alloy black layer 132 ofthe anodic structure A3. Additionally, the first thin platinum alloyblack layer 152 is preferably covered on the surface of the ionicexchange membrane 2 or the platinum alloy carbon support layer 151. Theplatinum alloy carbon support layer 151 can be a low catalytic platinumalloy carbon support layer (not shown in Figs.), having a combinationsimilar to the low catalytic platinum alloy carbon support layer 135 ofthe anodic structure A3.

In FIG. 7B, a reference signal B5 represents a fuel concentration curvewhen the fuel travels through the anodic structure A5. The fuelconcentration curve B5 obviously declines when the fuel travels throughthe platinum alloy carbon support layer 151 and the first thin platinumalloy black layer 152, i.e., most of the fuel in the anodic structure A5has a complete reaction. The distribution of the fuel concentration canbe controlled by regulating the percentage of the platinum alloy carbonsupport layer 151 and the first thin platinum alloy black layer 152, toconsume the fuel traveling through the anodic structure A5 and toincrease performance of the fuel cell.

The following cathode structures C1, C2, C3, C4 and C5 are fiveexemplary embodiments of the cathode structure 72.

In FIG. 8, the cathode structure C1 comprises a carbon support layer 312and a second substrate 311. The carbon support layer 312 sequentiallycomprises a platinum catalytic carbon support layer 317 disposed next tothe ionic exchange membrane 2 and a non-catalytic carbon support layer318. The platinum catalytic carbon support layer 317 comprises aplurality of platinum catalytic carbon supports 314 and an appropriatelyof second polymers 315. The platinum catalytic carbon supports 314comprises a plurality of carbon support particles 116 and a plurality ofplatinum catalytic particles 313 dispersed on surfaces of the carbonsupport particles 116. The platinum catalytic carbon supports 314 arelinked by the second polymers 315 to form the platinum catalytic carbonsupport layer 317. A second non-catalytic carbon support layer 318comprises a plurality of carbon support particles 116 and a plurality ofthird polymers 316 dispersed on surfaces of the carbon support particles116. The carbon support particles 116 are linked by the polymers 316 toform the non-catalytic carbon support layer 318. The carbon supportparticles 116 are preferably made of conductive and anti-corrosivecarbon material. The second polymers 315 are preferably made ofNafion®/Nafion® derivatives, non-perfluoro chemicals and derivativesthereof, or hydrocarbon, and the third polymers 316 are preferably madeof perfluoro chemicals and derivatives thereof, non-perfluoro chemicalsand derivatives thereof, or hydrocarbon. The first substrate layer 311can be a carbon substrate, and the non-catalytic carbon support layer318 regulates the diffusion rate of the oxygen and serves as a bumpinglayer between the platinum catalytic carbon support layer 317 and thesecond substrate 311. Note that the platinum catalytic carbon supportlayer 317 catalyzes oxygen located in the cathode structure C1 toperform a reduction reaction.

In FIG. 9, the cathode structure C2 sequentially comprises a platinumalloy black layer 332 disposed next to the ionic exchange membrane 2, anon-catalytic carbon support layer 321 and a second substrate 311. Theplatinum alloy black layer 332 comprises a plurality of platinumcatalytic particles 313 and an appropriately polymers 315, and theplatinum catalytic particles 313 are linked by the polymers 315 to formthe platinum alloy black layer 332. The configuration of thenon-catalytic carbon support layer 321 of the cathode structure C2 issimilar to the non-catalytic carbon support layer 318 of the cathodestructure C1, and the platinum alloy black layer 332 catalyzes oxygenlocated in the cathode structure C2 to perform a reduction reaction.

In FIG. 10, the cathode structure C3 sequentially comprises a platinumalloy black layer 332 disposed next to the ionic exchange membrane 2, acarbon support layer 331 and a second substrate 311. The second platinumalloy black layer 332 is preferably dispersed on the surface of theionic exchange membrane 2. The second thin platinum alloy black layer332 comprises a plurality of platinum alloy particles 115 and anappropriately of second polymers 315. The platinum alloy particles 115are linked by the polymers 315 to form the second thin platinum alloyblack layer 332. The second thin platinum alloy black layer 332 is athickly and densely catalytic layer, and the platinum alloy particlesare formed by platinum (Pt) combined with components such as Sn, Mo, Rh,W, Pd, Ir or Au. The carbon support layer 331 comprises a platinumcatalytic carbon support layer 333 disposed next to the second thinplatinum alloy black layer 332 and a non-catalytic carbon support layer334. The platinum catalytic carbon support layer 333 comprises aplurality of platinum catalytic carbon support particles 314 and aappropriately polymers 315, and the platinum catalytic carbon supportparticles 314 comprises a plurality of carbon support particles 116 anda plurality of platinum catalytic particles 313 dispersed on surfaces ofthe carbon support particles 116. The platinum catalytic carbon supportparticles 314 are linked by the polymers 315 to form the platinumcatalytic carbon support layer 333. The configuration of thenon-catalytic carbon support layer 334 of the cathode structure C3 issimilar to the non-catalytic carbon support layer 318 of the cathodestructure C1. The non-catalytic carbon support layer 334 comprises aplurality of carbon support particles 116 which are made of conductiveand anti-corrosive carbon material. The second thin platinum alloy blacklayer 332 consumes the fuel traveling through the ionic exchangemembrane 2 and the cathode structure C3 from the anodic structure 71,and the platinum catalytic carbon support layer 333 catalyzes oxygenlocated in the cathode structure C3 to perform a reduction reaction.

In FIG. 11, the cathode structure C4 sequentially comprises a secondthin platinum alloy black layer 344 disposed next to the ionic exchangemembrane 2, a platinum catalytic layer 342 and a second substrate 311.The configuration of the second thin platinum alloy black layer 344 ofthe cathode structure C4, similar to the second thin platinum alloyblack layer 332, comprises the platinum alloy particles 115 and thesecond polymers 315, and the second thin platinum alloy black layer 344is formed by the second polymers 315 linked by the platinum alloyparticles 115. The platinum catalytic layer 342 comprises a platinumblack layer 343 disposed next to the second thin platinum alloy blacklayer 344 and a second non-catalytic carbon support layer 341. Theplatinum black layer 343 comprises a plurality of platinum catalyticparticles 313 and an appropriately of second polymers 315. The platinumcatalytic particles 313 are linked by the second polymers 315 to formthe platinum black layer 343. The configuration of the secondnon-catalytic carbon support layer 341 of the cathode structure C4,similar to the non-catalytic carbon support layer 318 of the cathodestructure C1, comprises a plurality of carbon support particles 116which are made of conductive and anti-corrosive carbon material. Thesecond thin platinum alloy black layer 344 consumes the fuel travelingthrough the ionic exchange membrane 2 and the cathode structure C4 fromthe anodic structure 71, and the platinum black layer 343 catalyzesoxygen located in the cathode structure C3 to perform a reductionreaction.

In FIG. 12, the cathode structure C5 sequentially comprises a secondthin platinum alloy black layer 354 disposed next to the ionic exchangemembrane 2, a platinum catalytic layer 352 and a second substrate 311.The configuration of the second thin platinum alloy black layer 354 ofthe cathode structure C5, similar to the second thin platinum alloyblack layer 332 of the cathode structure C3, comprises a plurality ofplatinum alloy particles 115 and a appropriately of second polymers 315,and the second thin platinum alloy black layer 354 is formed by thesecond polymers 315 linked by the platinum alloy particles 115. Theplatinum catalytic layer 352 comprises a platinum black layer 353disposed next to the second thin platinum alloy black layer 354 and aplatinum catalytic carbon support layer 351. The configuration of theplatinum black layer 353 of the cathode structure C5, similar to theplatinum black layer 343 of the cathode structure C4, comprises aplurality of platinum catalytic particles 313 and a appropriately ofsecond polymers 315, and the platinum catalytic particles 313 are linkedby the second polymers 315 to form the platinum black layer 353. Theconfiguration of the platinum catalytic carbon support layer 351 of thecathode structure C5, similar to the platinum catalytic carbon supportlayer 333 of the cathode structure C3, comprises a plurality of platinumcatalytic carbon supports 314 and a appropriately of second polymers315. The platinum catalytic carbon supports 314 comprises a plurality ofcarbon support particles 116 and a plurality of platinum catalyticparticles 313 dispersed on surfaces of the carbon support particles 116,and the platinum catalytic carbon support layer 351 is linked by thesecond polymers 315 to form the platinum catalytic carbon supports 314.

FIG. 13 is a diagram comparing the fuel crossover status of methanolfuel of liquid, gel, solid or gaseous organic fuel (e.g., alcohol,aldehyde or acid) between the anodic structure A5 of the invention andthe conventional anodic structure A2. A 10% MeOH-N2 represents a 10%concentration of methanol fuel entering the anode structure and nitrogenentering the cathode structure. An ordinate and an abscissa representcurrent density and reaction potential, respectively. In the cathodestructure, a reduction reaction of hydrogen ions is performed by anexternal voltage. In the anode structure, an oxidation reaction ofmethanol fuel is performed. Methanol fuel, from the anode structure,throughout the ionic exchange membrane and diffusing to the cathodestructure, are oxidized at the cathode structure. When the reactionpotential is approximately equal to 0.8V, the rate of methanol fueldiffusing to the cathode structure is equal to the tested currentdensity, i.e., a current density determines the diffusion rate ofmethanol fuel. A reference signal B7 represents a diffusion rate curveof methanol fuel in the conventional anode structure A2, and a referencesignal B6 represents a diffusion rate curve of methanol fuel in theanode structure A5, wherein the diffusion rate curve B7 is higher thanthe diffusion rate curve B6. When the reaction potential is about 0.8V,the unitary current density of the diffusion rate curve B7 issubstantially higher than that of the diffusion rate curve B6 at 20%.That is to say, the amount of the methanol fuel crossover of theconventional anode structure A2 is far higher than that of the anodestructure A5.

FIG. 14A is a diagram comparing discharge performance at 10% fuelconcentration between the anodic structure A5 of the invention and theconventional anodic structure A2. A 10% MeOH-AIR represents a 10%concentration of methanol fuel entering the anode structure and airentering the cathode structure. The flow rate of methanol fuel in theanodic structure is four times value of the theoretical flow rate, andthe flow rate of air in the cathodic structure is eight times value ofthe theoretical flow rate. A left ordinate represents a dischargevoltage, a right ordinate represents a power density, and an abscissarepresents current density. A reference signal A2V represents adischarge voltage curve of the conventional anodic structure A2, and areference signal A5V represents a discharge voltage curve of the anodicstructure A5 of the invention. The discharge voltage curves A2V and A5Voperate under different current densities, respectively. A referencesignal A2P represents a power density curve of the conventional anodicstructure A2, and a reference signal A5P represents a power densitycurve of the anodic structure A5. The power density curves A2P and A5Poperate under different current densities, respectively. The dischargevoltage curve A5V is relatively higher than the discharge voltage curveA2V, and the maximum power density of the A5P is higher than the A2Pabout 18%. Thus, the performance of the anodic structure A5 of theinvention is superior to that of the conventional anodic structure A2.

FIG. 14B is a diagram comparing maximal power density at 10% fuelconcentration between the anodic structure A5 of the invention and theconventional anodic structure A2. An ordinate and an abscissa representmaximal power density and discharge test times, respectively. After aseries of discharge tests, the maximal power density of the anodicstructure A5 is smooth and stable, but the conventional anodic structureA2 gradually decreases.

FIG. 15A is a diagram comparing discharge performance at 20% of fuelconcentration between the anodic structure A5 of the invention and theconventional anodic structure A2. A 20% MeOH-AIR represents 20%concentration of methanol fuel entering the anode structure and airentering the cathode structure. The flow rate of methanol fuel in theanodic structure is four times value of the theoretical flow rate, andthe flow rate of air in the cathodic structure is four times value ofthe theoretical flow rate. A left ordinate represents a dischargevoltage, a right ordinate represents a power density, and an abscissarepresents current density. A reference signal A2V1 represents adischarge voltage curve of the conventional anodic structure A2, and areference signal A5V1 represents a discharge voltage curve of the anodicstructure A5 of the invention. The discharge voltage curves A2V1 andA5V1 operate under different current densities, respectively. Areference signal A2P1 represents a power density curve of theconventional anodic structure A2, and a reference signal A5P1 representsa power density curve of the anodic structure A5. The power densitycurves A2P1 and A5P1 operate under different current densities,respectively. The discharge voltage curve A5V1 is relatively higher thanthe discharge voltage curve A2V1, and the maximum power density of thedischarge voltage curve A5V is higher than the discharge voltage curveA2V about 45%. Thus, the performance of the anodic structure A5 of theinvention is superior to that of the conventional anodic structure A2.

FIG. 15B is a diagram comparing maximal power density at 20% fuelconcentration between the anodic structure A5 of the invention and theconventional anodic structure A2. An ordinate and an abscissa representmaximal power density and discharge test times, respectively. After thedischarge tests, the maximal power density of the anodic structure A5 issmooth and stable, but the conventional anodic structure A2 graduallydecreases. The maximal power density of the anodic structure A5 ishigher than the conventional anodic structure A2 about 45%. Thus, theperformance of the anodic structure A5 of the invention is superior tothat of the conventional anodic structure A2.

FIG. 16A is a diagram of maximal power density of the conventionalanodic structure A2 at different fuel concentrations. An ordinate and anabscissa represent maximal power density and discharge test times,respectively. Each curve represents the testing result of thecorresponding methanol fuels. The 30% MeOH, 20% MeOH and 10% MeOHrepresent 30%, 20% and 10% concentrations of methanol fuels entering theanode structure and air entering the cathode structure.

FIG. 16B is a diagram of maximal power density of the anodic structureA5 of the invention at different fuel concentrations. An ordinate and anabscissa represent maximal power density and discharge test times,respectively. The 30% MeOH, 20% MeOH and 10% MeOH represent 30%, 20% and10% fuel concentrations. In comparison with FIG. 16A, the maximal powerdensity of the anodic structure A5 is smooth and stable. Thus, thestability of discharge and performance of the anodic structure A5 of theinvention are superior to that of the conventional anodic structure A2.

A theoretical simulation is applicable in describing the superiority ofthe platinum alloy carbon support layer 712 and the first thin platinumalloy black layer 711 of the anodic structure 71 of the invention. Theconcentration of the methanol fuel distributed in the catalytic layer(e.g. platinum alloy carbon support layer or platinum alloy black layer)can be substantially calculated by the following expressions, wherein

${c(y)} = \frac{\frac{\cosh \left\lbrack {\Phi \; {^{\mu/2}\left( {y - 1} \right)}} \right\rbrack}{\left. {\cosh\left\lbrack {\Phi \; ^{\mu/2}} \right)} \right\rbrack}}{1 + {\Gamma \; ^{\mu}\frac{\tanh \left( {\Phi }^{\mu/2} \right)}{\Phi \; ^{\mu/2}}}}$${\Phi = \sqrt{\frac{k^{o}L_{y}}{D_{a}}}},\mspace{14mu} {\Gamma = \frac{\delta \; k^{o}}{D_{f}}}$

c(y) represents a function of concentration distribution of the methanolfuel, y represents locations of the methanol fuel located in thecatalytic layer, k^(o) represents a reaction constant, L_(y) representsa thickness of the catalytic layer, D_(a) represents a diffusioncoefficient of the methanol fuel located in the catalytic layer, D_(f)represents a diffusion coefficient of the methanol fuel located in thesubstrate, δ represents a thickness of the substrate, and μ representsthe equivalent potential.

The conventional anodic structures A1, A2 and the anodic structure 71 ofthe invention, for example, are incorporated into the described threeexpressions, and the results are respectively represented by threedifferent catalytic layers A, B and C in Table 1. The 20% PtRu/C of thecatalytic layer A represents having 20% Pt and Ru alloy particles ofplatinum alloy carbon support layer 112 of the conventional anodicstructure A1, the catalytic layer B containing PtRu black represents theplatinum alloy black layer 121 of the conventional anodic structure A2,and the catalytic layer C containing the platinum alloy carbon supportlayer 712 and the thin platinum alloy black layer 711 represents theplatinum alloy carbon support layer 712 and the first thin platinumalloy black layer 711 of the anodic structure 71 of the invention.

Table 1 represents the required thickness and weight of the catalyticlayers A, B and C, to prevent the methanol fuels crossover from anode tocathode. Based on the table 1. The amount of total catalyst of thecatalytic layer C is less than that of the catalytic layers A and B athalf. Thus, the cost of catalytic material of the catalytic layer C islower than that of the catalytic layers A and B.

Catalytic Catalytic Catalytic layer A layer B layer C Configuration offirst layer 20% PtRu/C PtRu black 20% PtRu/C Thickness of first layer,μm 178 16 25 Configuration of second layer None None PtRu blackThickness of second layer, μm None None  5 Amount of total  5  5  2.3catalyst, mg/cm²

FIG. 17 is a simulated diagram of fuel concentration distribution ofseveral catalytic layers based on the function c(y) of concentrationdistribution of the methanol fuel. An ordinate and an abscissa representconcentration of the methanol fuel and the location of the methanol fuelin the catalytic layer. A reference signal PA represents a concentrationdistribution curve of the methanol fuel of the catalytic layer A, areference signal PB represents a concentration distribution curve of themethanol fuel of the catalytic layer B, and a reference signal PCrepresents a concentration distribution curve of the methanol fuel ofthe catalytic layer C. The locations of the concentration distributioncurves PA, PB and PC, corresponding to zero of the ordinate andapproaching to the abscissa, represent the thicknesses required by thecatalytic layers A, B and C when the corresponding methanol fuels arecompletely consumed, respectively. It is understood that the greatestthickness is required by the catalytic layer A, the least thickness isrequired by the catalytic layer B, and the thickness of the catalyticlayer C ranges between the thicknesses required by the catalytic layersA and B. The greater the thickness of the catalytic layer, such as thecatalytic layer A, the greater the number of cracks formed during themanufacturing process of the electrode. On the other hand, a thinnercatalytic layer, such as the catalytic layer B, has less catalystutilization and the higher material cost. Note that the thickness of thecatalytic layer C ranges between the thicknesses required by thecatalytic layers A and B excludes the defections of the catalytic layersA and B and make use of the catalyst thereof.

The invention provides the combination of the platinum alloy carbonsupport layer 712 and the first thin platinum alloy black layer 711 ofthe anodic structure 71, to solve the fuel crossover problems of theconventional arts. Thus, the defects the required thickness of theplatinum alloy carbon support layer 112 of the conventional anodicstructure A1 can be reduced, the path of carbon dioxide in the platinumalloy carbon support layer 112 of the anodic structure A2 is reduced,the reaction power density is increased, and the cost of material of thefuel cell is reduced.

While the invention has been described by way of example and in terms ofthe preferred embodiments, it is to be understood that the invention isnot limited to the disclosed embodiments. To the contrary, it isintended to cover various modifications and similar arrangements (aswould be apparent to those skilled in the art). Therefore, the scope ofthe appended claims should be accorded the broadest interpretation so asto encompass all such modifications and similar arrangements.

1. An electrode structure for a fuel cell generating power by use of afuel for power generation, the electrode structure comprising: acathodic structure; an ionic exchange membrane disposed next to thecathodic structure; and an anodic structure, comprising a first thinplatinum alloy black layer disposed next to the ionic exchange membrane,a catalytic platinum alloy carbon support layer, a non-catalytic carbonsupport layer and a first substrate layer, wherein the catalyticplatinum alloy carbon support layer and the non-catalytic carbon supportlayer are disposed between the first thin platinum alloy black layer andthe first substrate layer, such that a combination of the non-catalyticcarbon support layer, the catalytic platinum alloy carbon support layerand the first thin platinum alloy black layer reduces crossover of thefuel from the anodic structure to the cathodic structure.
 2. Theelectrode structure as claimed in claim 1, wherein the catalyticplatinum alloy carbon support layer is disposed between the first thinplatinum alloy black layer and the non-catalytic carbon support layer.3. The electrode structure as claimed in claim 1, wherein thenon-catalytic carbon support layer comprises a plurality of carbonsupport particles and a appropriately polymers dispersed on surfaces ofthe carbon support particles, and the carbon support particles arelinked by the polymers to form the non-catalytic carbon support layer,and the carbon support particles are conductive and anti-corrosivecarbon material.
 4. The electrode structure as claimed in claim 1,wherein the catalytic platinum alloy carbon support layer comprises aplurality of platinum alloy carbon support particles containing aplurality of platinum alloy particles.
 5. The electrode structure asclaimed in claim 1, wherein the first thin platinum alloy black layer isformed on the ionic exchange membrane or the catalytic platinum alloycarbon support layer.
 6. The electrode structure as claimed in claim 1,wherein the first substrate layer comprises a carbon substrate.
 7. Theelectrode structure as claimed in claim 1, wherein the first thinplatinum alloy black layer comprises a appropriately polymers and aplurality of platinum alloy particles linked by the polymers, to formthe first thin platinum alloy black layer.
 8. The electrode structure asclaimed in claim 1, wherein the catalytic platinum alloy carbon supportlayer comprises a plurality of carbon support particles, a plurality ofplatinum alloy particles, and a appropriately polymers dispersed onsurfaces of the carbon support particles, wherein the carbon supportparticles are linked by the polymers to form the catalytic platinumalloy carbon support layer.
 9. The electrode structure as claimed inclaim 1, wherein the fuel cell generates power by use of a fuelcomprising an organic fuel comprising available fuels of liquid, gel,solid or gaseous types which contain alcohol, aldehyde or acid.
 10. Apower generation fuel cell, comprising: a fuel; and an electrodestructure used to actuate the fuel to generate electricity, comprising:a cathodic structure; an ionic exchange membrane disposed next to thecathodic structure; and an anodic structure, comprising a first thinplatinum alloy black layer disposed next to the ionic exchange membrane,a catalytic platinum alloy carbon support layer, a non-catalytic carbonsupport layer and a first substrate layer, wherein the catalyticplatinum alloy carbon support layer and the non-catalytic carbon supportlayer are disposed between the first thin platinum alloy black layer andthe first substrate layer, such that a combination of the non-catalyticcarbon support layer, the catalytic platinum alloy carbon support layerand the first thin platinum alloy black layer reduces crossover of thefuel from the anodic structure to the cathodic structure.
 11. The powergeneration fuel cell as claimed in claim 10, wherein the catalyticplatinum alloy carbon support layer is disposed between the first thinplatinum alloy black layer and the non-catalytic carbon support layer.12. The power generation fuel cell as claimed in claim 10, wherein thenon-catalytic carbon support layer comprises a plurality of carbonsupport particles and a appropriately polymers dispersed on surfaces ofthe carbon support particles, and the carbon support particles arelinked by the polymers to form the non-catalytic carbon support layer,and the carbon support particles are conductive and anti-corrosivecarbon material.
 13. The power generation fuel cell as claimed in claim10, wherein the catalytic platinum alloy carbon support layer comprisesa plurality of platinum alloy carbon support particles containing aplurality of platinum alloy particles.
 14. The power generation fuelcell as claimed in claim 10, wherein the first thin platinum alloy blacklayer is formed on the ionic exchange membrane or the catalytic platinumalloy carbon support layer.
 15. The power generation fuel cell asclaimed in claim 10, wherein the first substrate layer comprises acarbon substrate.
 16. The power generation fuel cell as claimed in claim10, wherein the first thin platinum alloy black layer comprises aappropriately polymers and a plurality of platinum alloy particleslinked by the polymers, to form the first thin platinum alloy blacklayer.
 17. The power generation fuel cell as claimed in claim 10,wherein the catalytic platinum alloy carbon support layer comprises aplurality of carbon support particles, a plurality of platinum alloyparticles, and a appropriately polymers dispersed on surfaces of thecarbon support particles, wherein the carbon support particles arelinked by the polymers to form the catalytic platinum alloy carbonsupport layer.
 18. The power generation fuel cell as claimed in claim10, wherein the fuel comprises an organic fuel comprising availablefuels of liquid, gel, solid or gaseous types which contain alcohol,aldehyde or acid.